Hobart Welding Products OM-240 438E manual

Champion Elite Processes Description ® Stick (SMAW) W elding Engine Driven Welding Generator OM-240 438E 201 1 − 03[...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 ................................ 1-1. Symbol Usage 1 ....................................................................... 1-2. Arc W elding Hazards 1 ................................................................. 1-3. Engine Hazards 3 .................................[...]

T ABLE OF CONTENTS 8-6. Overload Protection 38 .................................................................. 8-7. Servicing Optional Spark Arrestor 38 ....................................................... SECTION 9 − TROUBLESHOOTING 39 .......................................................... 9-1. W elding T roubleshooting 39 ............[...]

OM-240 438 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2010 − 03 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The p[...]

OM-240 438 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation [...]

OM-240 438 Page 3 1-3. Engine Hazards BA TTER Y EXPLOSION can injure.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables, battery charging cables (if applicable), or servicing battery .  Do not allow tools to cause sparks when worki[...]

OM-240 438 Page 4 1-4. Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill.  Incorrect installation or operation of this unit could result in equipment failure and personal injury . Only qualified persons should install, op - erate, and service this unit according to its Owner’ s Manual, industry standards, and na- tional, state, and loca[...]

OM-240 438 Page 5 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . COMPRESSED AIR can injure or kill.  Before working on compressed air system, turn off and lockout/tagout unit, release pres- sure, and be sure air pressure cannot be a[...]

OM-240 438 Page 6 WELDING WIRE can injure.  Do not press gun trigger until instructed to do so.  Do not point gun toward any part of the body , other people, or any metal when threading welding wire. OVERUSE can cause OVERHEA TING.  Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before starting to we[...]

OM-240 438 Page 7 1-8. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding an d Cutting, American W elding Society Standard A WS F4.1, from [...]

OM-240 438 Page 8 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_rom_2010 − 03 Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification des symboles DANGER! − Indiq[...]

OM-240 438 Page 9 LES PIÈCES CHAUDES peuvent provoquer des brûlures.  Ne pas toucher à mains nues les parties chau- des.  Prévoir une période de refroidissement avant de travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman- dé s et porter des gants de soudage et des vêtements épais pour ?[...]

OM-240 438 Page 10 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.  Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.  Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone o ù s e dérou[...]

OM-240 438 Page 1 1 LE S ÉTINCELLES À L ’ÉCHAPPEMENT peuvent provoquer un incendie.  Empêcher les étincelles d’échappement du moteur de provoquer un incendie.  Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur . LES PIÈCES CHAUDES peuvent provoquer des brûlures.  Ne pas toucher des parties chaudes à m[...]

OM-240 438 Page 12 un médecin familiarisé avec ce type de blessure, faute de quoi la gangrène pourrait apparaître. Les PIÈCES MOBILES peuvent causer des blessures.  S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors.  Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispos[...]

OM-240 438 Page 13 Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures.  Détendre la pression pneumatique des outils et circuits avant d’entretenir , ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du compresseur . Les PIÈCES MOBILES peuv[...]

OM-240 438 Page 14 LES CHARGES ÉLECTROST A TI - QUES peuvent endommager les circuits imprimés.  Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.  Utiliser des pochettes et des boîtes antistatiques pour stocker , déplacer ou expédier des cartes de circuits imprimes. UNE REMORQUE QUI BASCULE peu[...]

OM-240 438 Page 15 2-8. P ri nci pal es n or m es de sé cur i té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding an d Cutting, American W elding Society Standard[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 16 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check V alve Clearance Do not switch w[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 17 4-2. Dimensions, W eights, And Operating Angles 244 029-A / 244 030-A / 244 031-A 20 ° 20 ° 20 ° 20 ° ! Do not exceed tilt angles or engine could be damaged or unit could tip. ! Do not move or operate unit where it could tip. W eight: 562 lb (254 kg) Lifting Ey[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 18 4-3. Dimensions For Units With Optional Running Gear Dimensions 804 937-B Height All Running Gear Options: 42-1/2 in. (1079 mm) (T o T op Of Handle Assembly) A Protective Cage Width: 26 in. (660 mm) B Running Gear Width: 32 in. (813 mm) C Protective Cage Length: 48 i[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 19 4-5. V olt-Ampere Curves 240 426-A / 240 427-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of a ll other settings fall between the curves shown. A. For CC/AC Mode B. For CC/DC Mode[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 20 4-6. Fuel Consumption 202 094-A On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration. W elding at 150 amps at 40% duty cycle uses approximately 3/4 gal- lon per hour , or about 16 hours of operation. 4-7. Gene[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 21 SECTION 5 − INST ALLA TION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write seria[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 22 ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ! Also see A WS Safety & Health Fact Sheet No. 29, Grounding of Portable And V ehicle Mounted W elding Generators. ! Bed liners, shipping skids, an d some[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 23 5-4. Engine Prestart Checks 244 033-A / 217 015-A Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.  Follow run-in procedure in en- gine manual. NOTICE − This unit has a low oil pressure shutdown switch[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 24 5-5. Installing Exhaust Pipe 803 751 / Ref. 281 080-A ! Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. ! Point exhaust pipe in desired di- rection but always away from front p[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 25 ! Stop engine. ! Failure to properly connect weld cables may cause exces- sive heat and start a fire, or damage your machine.  Do not place anything between weld cable terminal and cop- pe r bar . Make sure that the sur- faces of the weld cable termi- nal and co[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 26 5-8. Selecting Weld Cable Sizes* NOTICE − The T otal Cable Length in W eld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 10 0 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 27 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Pr ofessional W elding Car eer Now![...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 28 SECTION 6 − OPERA TING THE WELDING GENERA TOR 4 1 3 6 6-1. Front Panel Controls 281 080-A 1 Engine Control Switch Use switch to start engine, select speed, and stop engine. In Run/Idle position, engine runs a t idle speed at no load, and weld/power speed under load[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 29 6-2. Cold Weather Engine Operation Ref. 240 947 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the rela- tive humidity is [...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 30 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP , ROUGH HIGH SP A TTER GENERAL SMOOTH, EASY , F AST LOW HYDROGEN, STRONG SMOOTH, EASY , F ASTER CAST IRON ST AINLESS DEEP DEEP LOW MED LOW LOW LOW LOW ALL ALL ALL ALL ALL FLA T HORIZ FILLET ALL ALL EP EP EP ,EN E[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 31 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT 7-1. Standard Receptacles 244 029-A / 281 080-A ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Generator power decreases as weld current increases . Set Fine Control R1 at 10 for fu[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 32 7-2. Simultaneous W eld And Power W eld Current in Amperes T otal Power in Watts 120 V Full kV A Receptacle Amperes 240 V Full kV A Receptacle Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 1 1,000 92 46 7-3. Wiring Optional 240 V olt Plug plug1 [...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 33 SECTION 8 − MAINTENANCE 8-1. Maintenance Label[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 34 8-2. Routine Maintenance ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change ?[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 35 ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner Was h precleaner with soap and wa- ter solution. Allow precleaner to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into precleaner. Squeeze out exces[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 36 8-4. Changing Engine Oil, Oil Filter , and Fuel Filter 244 033-A / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. ! Close valve and valve cap before adding o[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 37 8-5. Adjusting Engine Speed 244 033-A / 244 034-A After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Turn Fine Control to 10. Remove rear panel and air cleaner to access i[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 38 8-6. Overload Protection 244 029-A ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 10-1 ) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low . 2 Fuse F2 (See Section 10-1 ) F2 protects the [...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 39 SECTION 9 − TROUBLESHOOTING 9-1. W elding T roubleshooting T rouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections. Check fuse F1, and replace if open (see Section 8-6). Have Factory A[...]

 A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 40 T rouble Remedy No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit. Check fuses F1 and F2, and replace if open (see Section 8-6). Check plug PLG6 connection. Have Factory Authorized Service Agent check brushes[...]

 A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 41 T rouble Remedy Battery Discharges between uses. Clean battery , terminals, and posts with baking soda and water solution; rinse with clear water . Periodically recharge battery (approximately every 3 months). Replace battery . Check voltage regulator and connectio[...]

OM-240 438 Page 42 SECTION 1 1 − ELECTRICAL DIAGRAMS Figure 1 1-1. Circuit Diagram For Welding Generator[...]

OM-240 438 Page 43 240 424-B[...]

OM-240 438 Page 44 SECTION 12 − GENERA TOR POWER GUIDELINES  The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. 12-1. Selecting Equipment gen_pwr 2010 − 04 − ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Cas[...]

OM-240 438 Page 45 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #8 A WG or larger insulated copper wire. 3 Ground Device  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring syst[...]

OM-240 438 Page 46 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Start ing W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 [...]

OM-240 438 Page 47 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 [...]

OM-240 438 Page 48 12-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not[...]

OM-240 438 Page 49 12-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground thi[...]

OM-240 438 Page 50 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

OM-240 438 Page 51 SECTION 13 − STICK WELDING (SMA W) GUIDELINES 13-1. Stick Welding Procedure stick 2010 − 02 − 151 593 ! Weld current starts when electrode touches work- piece. ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible[...]

OM-240 438 Page 52 13-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELE[...]

OM-240 438 Page 53 13-4. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° 10 ° -30 ° 1 End View Of W ork Angle 2 Side View Of Electrode Angle 1 1 2 2 Groove Welds Fillet Welds 13-5. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Pen[...]

OM-240 438 Page 54 13-7. Conditions That Affect W eld Bead Shape S-0061 Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle Electrode Angle Arc Length T ravel Speed  Weld bead shape is affected by electrode angle, arc length, travel speed, and thick- ness of base metal. 13-8. El[...]

OM-240 438 Page 55 13-9. Groove (Butt) Joints S-0062 1 T ack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. 2 Square Groove Weld Good for materials up t o 3/16 in. (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in. (5-19 mm) thick. Cut bev[...]

OM-240 438 Page 56 13-12. Weld T est S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in. 1/4 in. 3 2 1 2 T o 3 in. 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 13-13. T roubleshooting Porosity − small cavities or holes resulting from gas pockets in weld metal. Possible Causes [...]

OM-240 438 Page 57 Lack of Penetration Good Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle. I[...]

OM-240 438 Page 58 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm 5/16 in .3125 in 1[...]

Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 201 1 − 01 Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hoba[...]

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 201 1 Hobart Welding Products. 201 1 − 01 Hoba rt W elding P roduc ts An Illinois T ool W orks Company 600 W est Main Street Tr oy , OH 45373 USA For T echn ical Assistance: Call1-800-332-3281 Fo r Liter atur e Or N ea rest Dea le r: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date [...]